BACKGROUND OF THE INVENTION
The present invention relates to a novel rotor
provided with permanent magnets for a rotating electric
machine, a method of fabricating the rotor, a rotating
electric machine, and a gas turbine power plant.
Fig. 10 is a sectional view of a prior art rotor
(prior art example 1) for a rotating electric machine. This
prior art rotor has a shaft 1, an annular permanent magnet 2
put on the shaft 1, and a holding ring 3a fixedly put on the
permanent magnet 2 by shrinkage fit or press fit. The
annular permanent magnet 2 is a monolithic, hollow,
cylindrical member, or a hollow cylindrical member formed by
assembling a plurality of permanent magnets. The holding
ring 3a prevents the fracturing and scattering of the
annular permanent magnet 2 by centrifugal force. Usually,
the holding ring is formed of nonmagnetic material, such as
a nickel-base alloy, a titanium alloy or a carbon-fiber-reinforced
plastic (CFRP).
Fig. 11 is a sectional view of a prior art rotor
(prior art example 2) disclosed in Japanese Patent Laid-open
No. 10-23695 for a rotating electric machine. This prior
art example 2 is provided with a radially magnetized
permanent magnet 2b, and a holding ring formed by assembling
nonmagnetic segments 3a and magnetic segments 3b.
When the rotor in the prior art example 1 shown in
Fig. 10 is used, the magnetic gap between the permanent
magnet 2b and a stator, not shown, increases by a value
corresponding to the thickness of the holding ring 3a, which
deteriorates an electric characteristic, such as induced
voltage in stator coils or output of a generator.
The rotor in the prior art example 2 is provided with
the holding ring formed by assembling the nonmagnetic
segments 3a and the magnetic segments 3b to solve the
problem in the prior art example 1. A narrow magnetic gap
is formed in regions corresponding to the magnetic segments
3b, which is effective in preventing the deterioration of
the electric characteristic. However, since the permanent
magnet 2b of the prior art example 2 is radially magnetized,
magnetic flux density is distributed in the air gap, i.e.,
the distance between a surface of the rotor and the stator,
not the magnetic gap, in a magnetic flux density
distribution curve resembling a square wave as shown in Fig.
12A. Since the magnetic flux density distribution curve
includes many higher harmonics, stator core loss increases,
and vibrations are enhanced when the rotor rotates.
A Halbach magnetization method is used for
magnetizing the permanent magnet to create a magnetic field
in which magnetic flux density is distributed in the air gap
in a magnetic flux density distribution curve resembling a
sinusoidal wave as shown in Fig. 12B to solve those problems
including the increase of stator core loss and the
enhancement of vibrations when the rotor rotates. In the
rotor in the prior art example 1 provided with the permanent
magnet magnetized by the Halbach magnetization method, the
magnetic gap, i.e., the distance between the permanent
magnet and the stator, increases by a value corresponding to
the thickness of the holding ring of the nonmagnetic
material. Thus, the rotor has a defect to cause the
deterioration of the electric characteristic, such as
induced voltage in stator coils or output of a generator.
When the permanent magnet magnetized by the Halbach
magnetization method is used by the rotor in the prior art
example 1, magnetic loop circuits are formed in portions A
as shown in Fig. 13, the magnetic flux density of the
portions A increases and, in some cases, magnetic saturation
occurs. In such a case, the equivalent magnetic resistance
of the magnetic circuits increases, which causes the
deterioration of the electric characteristic, such as
induced voltage in stator coils or output of a generator.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention
to provide a rotor capable of reducing stator core loss and
vibrations when rotated, of providing high output and of
being formed in a small size for a rotating electric machine,
a method of fabricating the rotor, a rotating electric
machine, and a gas turbine power plant.
The present invention provides, to solve the
foregoing problems, a rotor for a rotating electric machine,
including a Halbach magnetized permanent magnet put on a
shaft, and a holding ring formed by circumferentially
alternately arranging nonmagnetic segments of a nonmagnetic
material and magnetic segments of a magnetic material, and
fixedly put on the permanent magnet.
Since the rotor including the Halbach magnetized
permanent magnet put on the shaft, and the holding ring
fixedly put on the permanent magnet and formed by
circumferentially arranging the nonmagnetic segments and the
magnetic segments is used in a rotating electric machine,
magnetic flux density is distributed in a sinusoidal
distribution curve. Consequently, the problems including
the increase of stator core loss and the enhancement of
vibrations generated when the rotor rotates can be solved,
the magnetic gap can be reduced in regions corresponding to
the magnetic segments of the holding ring, and hence the
deterioration of the electric characteristic can be avoided.
Since the magnetic segments of the holding ring are highly
permeable to magnetic flux, small magnetic loop circuits as
shown in Fig. 13 are hardly formed, and magnetic saturation
does not occur around the portions A; that is, the
equivalent magnetic resistance of the magnetic circuits does
no increase, and hence the deterioration of the electric
characteristic can be avoided. Consequently, the output of
the rotating electric machine increases and the rotating
electric machine operates at high efficiency.
According to the present invention, a method of
fabricating a rotor for a rotating electric machine,
including a shaft, a cylindrical permanent magnet put on the
shaft, and a cylindrical holding ring formed by alternately
arranging nonmagnetic segments of a nonmagnetic material and
magnetic segments of a magnetic material comprises the steps
of: orienting and forming the permanent magnet for Halbach
magnetization in forming the permanent magnet by sintering;
assembling the shaft and the permanent magnet; and fixedly
putting the holding ring on the permanent magnet by
shrinkage fit or press fit. The permanent magnet is
magnetized by Halbach magnetization after assembling the
rotor for a rotating electric machine.
According to the present invention, a method of
fabricating a rotor for a rotating electric machine,
including a shaft, an auxiliary ring put on the shaft, a
cylindrical permanent magnet put on the auxiliary ring, and
a cylindrical holding ring formed by alternately arranging
nonmagnetic segments of a nonmagnetic material and magnetic
segments of a magnetic material comprises the steps of:
orienting and forming the permanent magnet for Halbach
magnetization in forming the permanent magnet by sintering;
assembling the shaft, the auxiliary ring and the permanent
magnet; and fixedly fitting the shaft in the auxiliary ring
by cooling fit or press fit. The permanent magnet is
magnetized by Halbach magnetization after assembling the
rotor for a rotating electric machine.
According to the present invention, a rotating
electric machine includes the rotor fabricated by one of the
foregoing methods according to the present invention.
According to the present invention, a gas turbine
power plant comprises: a gas turbine, and a generator driven
by the gas turbine; wherein the generator is the foregoing
rotating electric machine according to the present invention.
The present invention is effectively applied to a gas
turbine power plant in which the rotor of the generator has
a diameter in the range of 50 to 300 mm, and is driven for
rotation at a high rotating speed in the range of 20,000 to
100,000 rpm.
Although it is preferable that the permanent magnet
is a monolithic, hollow or solid, cylindrical magnet, the
permanent magnet may be a sectional magnet formed by
successively bonding together a plurality of magnets with an
adhesive or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the invention will
become apparent from the following description of
embodiments with reference to the accompanying drawings in
which:
Fig. 1 is sectional view of a rotor in a first
embodiment according to the present invention for a rotating
electric machine; Fig. 2 is a schematic longitudinal sectional view of
the rotor shown in Fig. 1; Fig. 3 is a sectional view of the rotor shown in Fig.
1, showing magnetic lines of force; Fig. 4 is a sectional view of a rotating electric
machine according to the present invention provided with the
rotor shown in Fig. 1; Fig. 5 is a sectional view of a rotor in a second
embodiment according to the present invention for a rotating
electric machine; Fig. 6 is a sectional view of a rotor in a third
embodiment according to the present invention for a rotating
electric machine; Fig. 7 is a sectional view of a rotor in a fourth
embodiment according to the present invention for a rotating
electric machine; Fig. 8 is a sectional view of a rotor in a fifth
embodiment according to the present invention for a rotating
electric machine; Fig. 9 is a diagrammatic view of a gas turbine power
plant in a sixth embodiment according to the present
invention equipped with a rotating electric machine
according to the present invention; Fig. 10 is a sectional view of a prior art rotor for
a rotating electric machine; Fig. 11 is a sectional view of another prior art
rotor for a rotating electric machine; Figs. 12A and 12B are diagrams showing the
distribution of magnetic flux density in an air gap; and Fig. 13 is a sectional view showing magnetic lines of
force around the rotor for a rotating electric machine.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First Embodiment
Fig. 1 is a sectional view of a two-pole rotor in a
first embodiment according to the present invention for a
rotating electric machine, in which the arrows indicate the
direction of magnetization. The rotor includes a shaft 1
playing a role of a center shaft, a cylindrical permanent
magnet 2a put on the shaft 1, and a cylindrical holding ring
3. The permanent magnet 2a is magnetized by Halbach
magnetization such that magnetic flux density is distributed
in a sinusoidal waveform as shown in Fig. 12B. The holding
ring 3 is formed by alternately arranging nonmagnetic
segments 3a of a nonmagnetic material and magnetic segments
3b of a magnetic material. Since this rotor creates a
magnetic field in which the magnetic flux density is
distributed in a sinusoidal waveform in an air gap, the
aforesaid problems including the increase of stator core
loss and the enhancement of vibrations when the rotor
rotates can be solved. Since the gap size of portions of
the magnetic gap corresponding to the magnetic segments 3b
is reduced, the deterioration of electric characteristic can
be avoided. Since the magnetic segments 3b of the holding
ring 3 are permeable to magnetic flux, the small magnetic
loop circuit as shown in Fig. 13 are hardly formed and
magnetic saturation does not occur around the portions A.
The equivalent magnetic resistance of the magnetic circuits
does not increase, and hence the deterioration of the
electric characteristic can be prevented. Consequently, the
output of the rotating electric machine increases and the
rotating electric machine operates at high efficiency.
The rotor for a rotating electric machine is
fabricated by assembling the shaft and the permanent magnet,
and fixedly putting the holding ring formed by alternately
arranging the nonmagnetic segments 3a and the magnetic
segments 3b on the permanent magnet by shrinkage fit or
press fit. The permanent magnet is magnetized by Halbach
magnetization after assembling the rotor for a rotating
electric machine.
Although the shaft 1 of the rotor in the first
embodiment is a sold, round shaft, a hollow, tubular shaft
may be used instead of the solid, round shaft for the same
effect.
Referring to Fig. 2 showing the rotor shown in Fig. 1
in a longitudinal sectional view, the cylindrical permanent
magnet 2a is mounted on a body part of the shaft 1, and the
cylindrical holding ring 3 put on the permanent magnet 2a.
Stop rings 5 are put on the opposite ends of the body part
of the shaft 1 to hold the permanent magnet 2a and the
holding ring 3 in place on the shaft 1. Shaft parts extend
from the opposite ends of the body part of the shaft 1,
respectively. The shaft 1 may be formed of either a
magnetic material, such as a low alloy steel, or a
nonmagnetic material, such as a Ni-base alloy.
Referring to Fig. 3 showing magnetic lines of force
in a magnetic field created by the rotor provided with the
permanent magnet magnetized by Halbach magnetization, the
magnetic lines of force are concentrated on the magnetic
segments 3b and, therefore, portions like the portions A
shown in Fig. 3 in which magnetic flux density is high are
not formed.
Referring to Fig. 4 showing a rotating electric
machine provided with the rotor in the first embodiment, a
stator has a stator core 6 formed by stacking silicon steel
plates and provided with slots 7, stator windings 8 wound in
the slots 7. The electric machine has also a case and
bearings held on the opposite ends of the case, which are
not shown in Fig. 4.
It is possible that a tensile stress a little less
than 1,000 MPa at a maximum is induced in the holding ring 3
of the rotor in the first embodiment when, for example, the
rotor has a diameter of 100 mm and rotates at a rotating
speed of 50,000 rpm. Therefore, the material forming the
holding ring 3 and the joints of the nonmagnetic segments 3a
and the magnetic segments 3b must have a tensile strength
greater than 1,000 MPa. Therefore, diffusion bonding may be
an effective bonding method of bonding the nonmagnetic
segments 3a and the magnetic segments 3b. The nonmagnetic
segment 3a and the magnetic segment 3b of the holding ring 3
are joined together by a joining procedure including the
steps of a diffusion bonding process, a solution treatment
and an aging treatment. It is important that heating
conditions suitable for the solution treatment and the aging
treatment of the nonmagnetic material and those suitable for
the solution treatment and the aging treatment of the
magnetic material are substantially the same. If the
heating conditions suitable for the nonmagnetic material and
those suitable for the magnetic material are different
considerably from each other, the nonmagnetic segments 3a
and the magnetic segments 3b cannot be simultaneously heat-treated,
and the respective strengths of portions, around
the joints, of the nonmagnetic segments 3a and the magnetic
segments 3b are reduced because those portions are affected
adversely by those different heating conditions unsuitable
for them. Therefore, the magnetic material and the
nonmagnetic material must be selected such that heat
treatment conditions suitable for treating the nonmagnetic
material and those suitable for treating the magnetic
material are substantially the same. Suitable magnetic
materials include maraging steels, stainless steels and die
steels. Suitable nonmagnetic materials include Ni-base
alloys and titanium alloys. It is particularly preferable
to form the nonmagnetic segments 3a of a titanium alloy and
to form the magnetic segments 3b of a maraging steel. The
cylindrical permanent magnet 2a is formed by sintering a
mass of an intermetallic compound containing a rare earth
element, such as NdFeB or SmCo.
When the nonmagnetic segments 3a and the magnetic
segments 3b are bonded together with an adhesive, the
nonmagnetic segments 3a and the magnetic segments 3b can be
individually processed by the solution treatment and the
aging treatment, and the thus treated nonmagnetic segments
3a and the magnetic segments 3b can be bonded together.
Therefore the difference in heat treatment conditions
between the nonmagnetic segments 3a and the magnetic
segments 3b is not a problem.
The holding ring may be formed of a composite
magnetic material that permits formation of local
nonmagnetic sections in the holding ring to avoid the
foregoing problem in bonding together the nonmagnetic
segments 3a and the magnetic segments 3b. For example, a
ferrite stainless composite material exhibits ferromagnetism
when heated at temperatures not higher than the ferrite-phase
(α-phase) temperature and becomes nonmagnetic when
treated by a solution treatment at a temperature not lower
than the austenite-phase (γ-phase) temperature and quenched.
When the holding ring 3 is formed of such a composite
magnetic material, the holding ring is free from problems
that arises in joining together the nonmagnetic segments 3a
and the magnetic segments 3b, and it is unnecessary to worry
about the reduction of the strength of the joints due to
defects and such.
Second Embodiment
Fig. 5 shows a two-pole rotor in a second embodiment
according to the present invention for a rotating electric
machine. This rotor includes a solid, cylindrical permanent
magnet 2a, and a cylindrical holding ring put on the
permanent magnet 2a. The permanent magnet 2a is magnetized
by Halbach magnetization. The holding ring is formed by
alternately arranging nonmagnetic segments 3a of a
nonmagnetic material and magnetic segments 3b of a magnetic
material. Since this rotor, similarly to the rotor in the
first embodiment, creates a magnetic field in which the
magnetic flux density is distributed in a sinusoidal
waveform in an air gap, the aforesaid problems including the
increase of stator core loss and the enhancement of
vibrations when the rotor rotates can be solved. Since the
gap size of portions of the magnetic gap corresponding to
the magnetic segments 3b is reduced, the deterioration of
electric characteristic can be avoided. Consequently, the
output of the rotating electric machine increases and the
rotating electric machine operates at high efficiency.
Materials, method of fabrication and method of magnetization
relating to the rotor in the second embodiment are the same
as those relating to the rotor in the first embodiment. As
shown in Fig. 5, lines of magnetic flux in the magnetic
field created by the permanent magnet 2a extend in a
direction perpendicular to the axis of the shaft 1.
Third Embodiment
Fig. 6 shows a two-pole rotor in a third embodiment
according to the present invention for a rotating electric
machine. This rotor includes a solid, cylindrical permanent
magnet 2a, a cylindrical holding ring put on the permanent
magnet 2a, and a nonmagnetic auxiliary ring 4 put on the
holding ring. The holding ring is formed by alternately
arranging nonmagnetic segments 3a of a nonmagnetic material
and magnetic segments 3b of a magnetic material. Even if
defects are formed in the joints of the nonmagnetic segments
3a and the magnetic segments 3b, and the nonmagnetic
segments 3a and the magnetic segments 3b are disconnected
from each other, the component parts of the rotor are
restrained from scattering by the auxiliary ring 4 to ensure
the safety of the surroundings of the rotor. Preferable
nonmagnetic materials for forming the auxiliary ring 4
include Ni-base alloys, titanium alloys, and carbon-fiber-reinforced
plastic. The construction of the rotor is the
same as that of the rotor in the first embodiment, and the
construction of a rotating electric machine provided with
the rotor in the third embodiment is the same as that of the
rotating electric machine provided with the rotor in the
first embodiment.
The rotor in the third embodiment is fabricated by
assembling the auxiliary ring 4, the permanent magnet 2a,
and the holding ring, and fitting the shaft in the auxiliary
ring 4 by press fit or cooling fit. The permanent magnet 2a
is magnetized by Halbach magnetization after the rotor has
been assembled.
Materials, method of fabrication, and method of
magnetization relating to the rotor in the third embodiment
excluding the auxiliary ring 4 are the same as those
relating to the rotor in the first embodiment. As shown in
Fig. 6, lines of magnetic flux in the magnetic field created
by the permanent magnet 2a extend in a direction
perpendicular to the axis of the shaft 1.
Fourth Embodiment
Fig. 7 shows a two-pole rotor in a fourth embodiment
according to the present invention for a rotating electric
machine. This rotor includes a solid, cylindrical permanent
magnet 2a, an inner nonmagnetic auxiliary ring 4 put on the
permanent magnet 2a, a holding ring put on the inner
auxiliary ring 4a, and an outer nonmagnetic auxiliary ring
4b put on the holding ring. The holding ring is formed by
alternately arranging the nonmagnetic segments 3a and the
magnetic segments 3b. The holding ring and the inner and
outer auxiliary rings 4a, 4b can be combined in a single
member. The auxiliary rings 4a, 4b reinforce the holding
ring. Thus, the assembly of the holding ring and the
auxiliary rings 4a, 4b has a strength higher than that of
the holding ring. Even if defects are formed in the joints
of the nonmagnetic segments 3a and the magnetic segments 3b,
and the nonmagnetic segments 3a and the magnetic segments 3b
are disconnected from each other, the component parts of the
rotor are restrained from scattering by the auxiliary rings
4a, 4b to ensure the safety of the surroundings of the rotor.
Preferable nonmagnetic materials for forming the auxiliary
rings 4a, 4b include Ni-base alloys, titanium alloys,
carbon-fiber-reinforced plastic.
The rotor in the fourth embodiment is fabricated by
assembling the permanent magnet 2a and the shaft, and
putting an annular member formed by putting the inner
auxiliary ring 4a on and fitting the outer auxiliary ring 4b
in the holding ring formed by alternately arranging the
nonmagnetic segments 3a and the magnetic segments 3b on the
assembly of the permanent magnet 2a and the shaft by press
fit or shrinkage fit. The permanent magnet 2a is magnetized
by Halbach magnetization after the completion of the rotor.
Materials relating to the rotor in the fourth
embodiment excluding the auxiliary rings 4a, 4b are the same
as those relating to the rotor in the first embodiment. As
shown in Fig. 7, lines of magnetic flux in the magnetic
field created by the permanent magnet 2a extend in a
direction perpendicular to the axis of the shaft 1.
Fifth Embodiment
Fig. 8 shows a four-pole rotor in a fifth embodiment
according to the present invention for a rotating electric
machine. The rotor in the fifth embodiment is provided with
a holding ring 3 formed by alternately arranging four
nonmagnetic segments 3a and four magnetic segments 3b.
Materials, method of fabrication and such relating to
the rotor in the fifth embodiment are the same as those
relating to the rotor in the first embodiment.
In an n-pole rotor, where n is six, eight or such, a
holding ring 3 is formed, similarly to the four-pole rotor
in the fifth embodiment, by alternately arranging n
nonmagnetic segments and n magnetic rings for the same
effect.
Sixth Embodiment
Fig. 9 shows a gas turbine power plant in a sixth
embodiment according to the present invention employing the
rotor in any one of the first to the fifth embodiment. The
gas turbine power plant is equipped with a compressor 7, a
combustor 8, a gas turbine 9 and a generator 10. The heat
of exhaust from the gas turbine 9 is used for generating
steam by a waste-heat boiler, and the steam generated by the
waste-heat boiler is used for driving a steam turbine, for
heating or such.
The rotor of the present invention for a rotating
electric machine is effectively applicable to a high-speed
generator that operates at a high operating speed in the
range of 20,000 to 100,000 rpm. The rotor reduces stator
core loss and vibrations when rotated, enhances the output
of the generator and enables forming the generator in a
small size.
The rotor of the present invention, for a rotating
electric machine, comprising the permanent magnet magnetized
by Halbach magnetization, and the holding ring formed by
alternately arranging the nonmagnetic segments and the
magnetic segments and put on the permanent magnet creates a
magnetic field in which magnetic flux density is distributed
in a sinusoidal waveform. Thus, the problems including the
increase of stator core loss and enhancement of vibration
when the rotor rotates can be solved. Since the gap size of
portions of the magnetic gap corresponding to the magnetic
segments is reduced, the deterioration of electric
characteristic can be avoided. Since the magnetic segments
of the holding ring are permeable to magnetic flux, small
magnetic loop circuits are hardly formed and magnetic
saturation does not occur around particular portions of the
shaft. The equivalent magnetic resistance of the magnetic
circuits does not increase, and hence the deterioration of
the electric characteristic can be prevented. Consequently,
the output of the rotating electric machine increases and
the rotating electric machine operates at high efficiency.
While the invention has been described in its
preferred embodiments, it is to be understood that the words
which have been used are words of description rather than
limitation and that changes within the purview of the
appended claims may be made without departing from the true
scope and spirit of the invention in its broader aspects.